The production of high-quality flexographic and rotogravure inks requires precise mixing, dispersion, and homogenization to achieve consistent color, viscosity, and performance for printing applications. Kady International, a leader in industrial mixing technology since 1949, provides advanced high-speed rotor-stator dispersion mills and mixing systems that streamline the ink manufacturing process. Based in Scarborough, Maine, their 50,000-square-foot facility produces innovative mixers, including top and bottom entry batch mixers and continuous flow mills, used globally in over 40 countries. These systems ensure superior ink quality for the printing industry, particularly for flexographic and rotogravure inks used in packaging, labels, and high-end graphics.
Flexographic and Rotogravure Ink Requirements
Flexographic and rotogravure inks demand fine particle dispersion, uniform color distribution, and stable viscosity to ensure smooth printing and vibrant results on substrates like paper, plastic, and foil. Flexographic inks, often water- or solvent-based, require thorough emulsification and pigment dispersion for flexible packaging and labels. Rotogravure inks, typically solvent-based, need high shear mixing to achieve fine particle sizes (below 20 microns) for detailed, high-volume printing like magazines and packaging. Kady International’s mixers address these needs by combining premixing and milling into a single, efficient step, reducing production time and ensuring consistent ink quality. Kady’s High-Speed Rotor-Stator Technology
Kady International’s mills, such as the Model 4C and 500B, utilize high-speed rotor-stator dispersion technology with rotor tip speeds up to 9,000 FPM, delivering a homogenous premix and dispersion in less time than traditional methods. The Kady PreMilling process integrates premixing and early milling, eliminating multiple media mill passes and reducing particle sizes to below 20 microns. This is critical for flexographic inks, ensuring smooth flow through anilox rollers, and for rotogravure inks, providing the fine dispersion needed for high-resolution gravure cylinders. The mills handle viscous fluids, pigments, and additives, achieving uniform color and stability without excessive heat buildup.Efficiency and Customization
Kady’s mixers, including bottom-entry designs unique to the industry, offer versatility for batch and continuous processing, ideal for ink manufacturers scaling from laboratory to high-volume production. Their systems support a range of ink formulations, including water-based, solvent-based, and UV-curable inks, with capabilities for dispersing, emulsifying, and homogenizing. Custom engineering ensures mixers meet specific viscosity and pigment requirements, while refurbished models like the 4C-75 and 500B-150 provide cost-effective solutions. In-house testing and on-site consulting optimize mixing processes, reducing production costs and equipment wear while enhancing ink performance.Benefits for Ink Manufacturers
By using Kady International mixers, ink manufacturers achieve faster production, higher flow rates, and reduced equipment costs compared to traditional media mills. The ability to handle diverse applications—pigment dispersion, varnish mixing, and fluid-based ink production—ensures flexibility for flexographic and rotogravure needs. With a global network of representatives and a commitment to customer service, Kady supports manufacturers in achieving consistent, high-quality inks that meet stringent printing standards.Contact Kady International to learn how our mixing solutions can work for you - call 207.883.4141 or contact us online.
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